Vehicle wheel spoke connection

ABSTRACT

A vehicle wheel, comprising a rim, a hub, a plurality of spokes extending between the rim and hub, a bracing element including a hole with a central axis, a sidewall, a longitudinally inward entrance, and at least one of an engagement surface and an engagement edge outward of the entrance, a connecting element connected to the bracing element, including an opening extending along an opening axis, and a multiplicity of prongs, with at least one of the prongs including a lateral overhang surface. The connecting element is resilient and may be flexed between collapsed and expanded orientations and is positioned within the hole, with the overhang surface overlying one of the engagement surface and engagement edge. The spoke is connected to the connecting element by a threaded engagement with the central opening.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority of the following U.S. provisional patent applications:

-   -   61/575,380, filed Aug. 19, 2011, and entitled “VEHICLE WHEEL         SPOKE CONNECTION”;     -   61/575,381, filed Aug. 19, 2011, and entitled “VEHICLE WHEEL         SPOKE CONNECTION”; and     -   61/575,374, filed Aug. 19, 2011, and entitled “VEHICLE WHEEL         SPOKE CONNECTION”.

BACKGROUND OF THE INVENTION

(1) Field of the Invention

This invention is related to the means of attachment between the spoke and the rim of a vehicle wheel and between the spoke and the hub of a vehicle wheel. This invention is particularly related to the connection of a spoke with a rim structure having a “double-wall” construction with an unpierced tire bed wall for tubeless tire applications.

(2) Description of the Related Art

Bicycle wheel rims have historically been constructed to accept pneumatic tires that are designed to work in conjunction with an inner tube. This is the standard of the industry and is the arrangement that we are all familiar with. In such a prior art configuration, the rim's tire bed includes a through-hole that is drilled through for passage of the spoke nipple. In a rim of “single-wall” construction, the tire bed and the spoke bed are shared such that the spoke nipple bears directly against the rim's tire bed. In a rim of “double-wall” construction, the rim has two lateral walls, a tire bed wall and a spoke bed wall, usually with a radial gap or cavity therebetween. The rim is drilled through both walls, piercing both the tire bed and the spoke bed walls, with the spoke bed recessed below the tire bed to accept the spoke nipples. Generally, the spoke is presented through the spoke bed from the inside diameter of the rim and the spoke nipple is presented for attachment to the spoke through the tire bed and from the outside diameter of the rim. With single-wall or double-wall rim constructions, a rim strip is utilized to protect the inner tube from the sharp edges associated with the holes in the tire bed wall and/or with the spoke nipples. With rims of double-wall construction, the rim strip also serves to prevent the inner tube from extruding through the drilled access openings in the tire bed.

With the recent advent of tubeless tire technology, where the conventional inner tube is eliminated and the tire's beads are sealed directly against the rim, it is desirable that the tire bed wall be sealed and airtight to prevent air leakage from the tire cavity. This typically involves a rim of double-wall construction where the tire bed is sealed while the spoke bed is then adapted to accept the spokes. One preferable method for sealing the tire bed is to eliminate the aforementioned spoke access holes in the tire bed. If the tire bed is not pierced for the spokes, then the only hole through the tire bed will be for the tire inflation valve, which may be constructed of rubber and is relatively easy to seal against the tire bed. An example of such a tubeless arrangement is outlined by Lacombe et al. in U.S. Pat. No. 6,443,533, where the tire bed remains unpierced and the spoke bed includes extruded spoke holes that are directly threaded with internal threads to accept special externally threaded spoke nipples.

Reference is also made to prior art UK Patent Application GB2479870A by Jonathan Thulbon. Thulbon shows his spoke (3) connected to his rim (4) by eyelets (7). This eyelet is a one-piece element with slots (74) to provide flexure for installation with his rim. Thulbon's arrangement has several shortcomings: Firstly, the single overlie engagement between Thulbon's spoke nipple and eyelet is located inwardly from the outboard surface of his spoke bed, which requires that his eyelet include longitudinally outward extension portions that surround the head of his nipple to engage his rim. These extension portions require that the corresponding hole in his rim be significantly larger than the head of his spoke nipple. This oversized hole serves to further weaken his rim in this highly-loaded area. Secondly, these extension portions also serve to laterally offset the overlie engagement between his rim and eyelet from the overlie engagement between his eyelet and nipple. This offset places additional tensile and bending stress on the eyelet due to spoke tension forces, further weakening his spoke connection. Thirdly, Thulbon does not contemplate a longitudinal engagement between his spoke and eyelet and instead utilizes only a single overlie engagement at a single longitudinal location. Such a single overlie engagement requires a very large laterally projected area of overlie to resist spoke tension loads, which results in a larger eyelet and a correspondingly larger hole in his rim.

SUMMARY OF THE INVENTION

The present invention utilizes an expandable connecting element or ferrule that is blindly inserted through a hole in the spoke bed. The connecting element expanded to engage the edge and/or adjacent surface at the distal end of the hole. The spoke or an intermediate element connected to the spoke is engaged to the connecting element to create a firm connection between the spoke and the spoke bed. It is noted that the spoke bed constitutes a portion of the rim or hub flange to which the connecting element is attached. As the novelty of a blind connection of the spoke is particularly advantageous in conjunction with rims associated with tubeless tires, most of the embodiments are shown with a spoke bed associated with the rim.

It is an object of the present invention to create a spoke connection: that may be blindly installed with the spoke bed of the rim and/or hub: that may leave the tire bed of the rim to remain unpierced; that may eliminate the necessity of a rim strip; that may permit a spoke connection that may otherwise be geometrically impossible by conventional means; and that may result in a robust connection capable of resisting spoke tension loads.

One aspect of the invention involves a method for assembling a wheel. For each of a number of spoke holes in the wheel rim, a resilient connecting element associated with a given spoke is inserted radially outward through the spoke hole in the spoke bed (or radially inwardly for a spoke bed associated with a hub). The connecting element may flex to expand and engage the edge or surface adjacent the distal end of the hole. Conversely, the connecting element may be contracted to permit its assembly through the spoke hole. A spoke is then connected to the connecting element, either directly or by means of an intermediate connecting element. This connection between spoke and connecting element preferably includes a longitudinal engagement such as a threaded engagement.

In various implementations, the connecting element may or may not include a flange, the connecting element may be keyed to the hole, the connecting element may be keyed to the spoke bed surface, the connector may be normally expanded or open or else may be normally unexpanded or collapsed, the connector may have a fully threaded or a partially threaded opening, the connecting element's opening axis may be parallel to the hole's axis or the opening's axis may be at an angle to the hole's axis, the connecting element may include an extension.

Another aspect of the invention involves a wheel. The wheel has a rim with a spoke bed having spoke holes and a tire bed radially outboard of the spoke bed and lacking holes aligned with the spoke holes. Spokes couple the rim to the hub with connecting elements coupling the spokes to the rim. Each connecting element has a first portion (i.e. collar portion) extending within an associated spoke hole. An opening of each connecting element accommodates either an associated spoke or an intermediate element coupled to the associated spoke. The connecting element has a second portion (i.e. enlarged portion) radially outboard of the spoke bed and cooperating with an outboard surface of the spoke bed to prevent radial inward movement of the associated spoke and permitting tension in the spoke to be transferred to the spoke bed. In various implementations, the connecting element may consist essentially of a single piece. The spoke or an intermediate element coupled to the spoke may have a threaded engagement with the connecting element. The spoke or an intermediate element coupled to the spoke may serve to maintain the connecting element in its open and expanded orientation and its engagement with the spoke bed. As disclosed herein, the connecting element may also be utilized to connect the spoke to a spoke bed of the hub shell in a manner similar to that described above.

Another aspect of the invention involves a wheel rim. The rim has a spoke bed with a number of spoke holes that are commonly produced by drilling. A tire bed is radially outboard of the spoke bed and lacks holes aligned with the spoke holes. Lateral walls extend radially outward from opposite sides of the tire bed and cooperate with the tire bed to form a tire well. The rim may be substantially unitarily formed from a light alloy (e.g., aluminum alloy) or a fiber composite. A clincher tire may be mounted in the tire well advantageously in the absence of a separate tube. A valve may be sealingly mounted in a valve hole in the tire bed and extending through a valve hole in the spoke bed for inflating the tire.

The present invention provides a spoke connection that may be blindly installed in the spoke bed. The connector may be economically produced using conventional manufacturing methods. The connection is easy to install and is serviceable in the field. The connection may be designed to provide a clean appearance with enhanced aesthetics. The connector may be made of high strength material(s), such as fiber-reinforced plastic or metals. The connector may have a large overlap with the spoke bed for increased robustness of the connection. The connector may be designed to minimize the size of the hole in the spoke bed, thereby increasing the strength of the bracing element (i.e. rim or hub). The connector may eliminate the necessity of a rim strip or rim tape. The resulting spoke connection is exceptionally robust and supports substantial spoke tension forces.

In contrast to prior art UK Patent Application GB2479870A by Jonathan Thulbon the connecting element of the present invention includes a longitudinal engagement to connect the spoke. The overlie engagement between the spoke (or an intermediate connecting element connected to the spoke) and the connecting element may be located longitudinally outwardly from the outboard surface of the spoke bed, which serves to minimize the tensile and bending stress on the connecting element due to spoke tension forces, further strengthening the spoke connection. Further, the longitudinal engagement of the present invention permits a comparatively larger surface area of engagement than a single engagement location, which reduces stresses on the connector and spoke and allows for a minimized connector geometry which requires a smaller hole in the spoke bed.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be more readily understandable from a consideration of the accompanying drawings, wherein:

FIG. 1 is a perspective view schematically illustrating the general configuration of a prior art vehicle wheel as applied to a bicycle wheel;

FIG. 2 a is an axial plan view illustrating a prior art bicycle wheel;

FIG. 2 b is a cross-section view of the prior art bicycle wheel of FIG. 2 a, as seen generally in the direction 15-15;

FIG. 2 c is a fragmentary view detailing the view illustrated in FIG. 2 b where the hub flange is shown in a partial cross-section to illustrate the connection with the spoke;

FIG. 3 a is a partial radial cross-sectional view of a prior art single-wall rim;

FIG. 3 b is a partial radial cross-sectional view of a prior art double-wall rim;

FIG. 4 is a cross-section view in the axial plane of a bicycle wheel, including an exemplary application of the present invention;

FIG. 5 a is an exploded perspective view of a first embodiment of the present invention, with the rim in cross section, describing a blind connection between the spoke and the rim, including an expandable connector;

FIG. 5 b is a cross section view, taken along 52-52, of the connector of the embodiment of FIG. 5 a;

FIG. 5 c is a cross section view, taken alone 52-52, of the sleeve of the embodiment of FIG. 5 a;

FIG. 5 d is an exploded perspective view of a the embodiment of FIG. 5 a, showing a first assembly step with the connector as assembled to the hole of the rim;

FIG. 5 f is a perspective view of a the embodiment of FIG. 5 d, showing a second assembly step with the sleeve and spoke as assembled to the connector;

FIG. 5 f is an exploded cross section view, taken along 52-52, of the embodiment of FIG. 5 a and corresponding to FIG. 5 a;

FIG. 5 g is an exploded cross section view, taken along 52-52, of the embodiment of FIG. 5 a, showing the initial stage of a first assembly step between the connector and the hole of the rim;

FIG. 5 h is an exploded cross section view, taken along 52-52, of the embodiment of FIG. 5 a and corresponding to the assembly sequence of FIG. 5 d, showing a completed first assembly step with the connector assembled to the rim;

FIG. 5 i is a cross section view, taken along 52-52, of the embodiment of FIG. 5 a and corresponding to the assembly sequence of FIG. 5 e, showing a second assembly step with the sleeve and spoke as assembled to the connector;

FIG. 5 j is a cross section view, taken along 52-52, of an alternative connector corresponding to the embodiment of FIG. 5 a, including partially threaded opening;

FIG. 5 k is an exploded cross section view, taken along 52-52, of an alternative connector corresponding to the embodiment of FIGS. 5 a, showing a first assembly step with the connector assembled to the rim, including a smooth opening;

FIG. 5L is a cross section view, taken along 52-52, of the embodiment of FIG. 5 k, showing a second assembly step with the sleeve and spoke as assembled to the connector in a self-tapping threaded engagement;

FIG. 5 m is a perspective view, of an alternative connector corresponding to the embodiment of FIG. 5 a, including three prongs;

FIG. 5 n is a cross section view, of an alternative connector corresponding to the embodiment of FIG. 5 a, including angled overhang surfaces;

FIG. 6 a is a partial exploded perspective view of a second embodiment of the present invention, describing a blind connection between the spoke and the spoke bed, including an expandable connector that is rotationally keyed to the spoke bed and an angle between the spoke bed hole and the connector opening;

FIG. 6 b is a cross section view, taken along 125-125, of the connector of the embodiment of FIG. 6 a;

FIG. 6 c is an exploded cross section view, taken along 125-125, of the embodiment of FIG. 5 a and corresponding to FIG. 5 a;

FIG. 6 d is an exploded cross section view, taken along 125-125, of the embodiment of FIG. 6 a, showing a completed first assembly step with the connector assembled to the spoke bed;

FIG. 6 e is a cross section view, taken along 125-125, of the embodiment of FIG. 6 a, showing a second assembly step with the sleeve and spoke as assembled to the connector;

FIG. 7 a is a partial exploded perspective view of a third embodiment of the present invention, describing a blind connection between the spoke and the spoke bed, including an expandable connector that is rotationally keyed to the face of the spoke bed, including notches of the connector engaged with projections on the surfaces of the spoke bed;

FIG. 7 b is a cross section view, taken along 163-163, showing the connector of FIG. 7 a;

FIG. 7 c is partial perspective view, of the embodiment of FIG. 7 a, showing a completed first assembly step with the connector assembled to the spoke bed;

FIG. 8 a is a partial exploded perspective view of a fourth embodiment of the present invention, describing a blind connection between the spoke and the spoke bed, including an expandable connector that is rotationally keyed to the spoke bed and nested curved contours between the overhang surfaces and flange of the connector and the spoke bed;

FIG. 8 b is a perspective view, of the connector of the embodiment of FIG. 8 a;

FIG. 8 c is an exploded cross section view, taken along 198-198, of the embodiment of FIG. 8 a, showing a completed first assembly step with the connector assembled to the spoke bed;

FIG. 9 a is a partial exploded perspective view of a fifth embodiment of the present invention, describing a blind connection between the spoke and the spoke bed, including an expandable connector with a base portion and without a flange;

FIG. 9 b is partial perspective view of the embodiment of FIG. 9 a, showing a completed first assembly step with the connector assembled to the spoke bed and the sleeve partially threaded into the connector;

FIG. 9 c is a partial perspective view of the embodiment of FIG. 9 a, showing a second assembly step with the sleeve and spoke as fully assembled to the connector;

FIG. 9 d is a partial cross section view, taken along 286-286 and corresponding to the embodiment of FIG. 9 a, of an alternative joining means between the sleeve and spoke, including a threaded engagement therebetween;

FIG. 9 e is a partial cross section view, taken along 286-286286 and corresponding to the embodiment of FIG. 9 a, of an alternative arrangement wherein the spoke is directly joined to the connector without an intermediate connecting means;

FIG. 10 a is partial perspective view of a sixth embodiment of the present invention, showing the sleeve, spoke, connector and spoke bed as joined together, including a connector with an extension;

FIG. 10 b is a side view of the connector of FIG. 10 a;

FIG. 10 c is a cross section view, taken along 229-229, of the connector of FIG. 10 a;

FIG. 11 a is a cross section view corresponding to the view of FIG. 5 f, of a seventh embodiment of the present invention, including a connector that is collapsed or “normally closed” prior to its assembly with the sleeve;

FIG. 11 b is a cross section view corresponding to the view of FIG. 5 g, of the embodiment of FIG. 11 a;

FIG. 11 c is a cross section view corresponding to the view of FIG. 5 i, of the embodiment of FIG. 11 a;

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 describes the basic configuration of an exemplary prior art vehicle wheel, in particular, a bicycle wheel 1, as well as a description of the direction conventions used throughout this disclosure. For clarity, the frame and the quick release skewer assembly are not shown in this figure. The hub shell 14 is rotatable about the axle 9 and includes at least two axially spaced hub flanges 16, each of which include a means for connecting with the spokes 2. Axle 9 includes end faces 11 a and 11 b that define the spacing of its mounting with the frame (not shown). The axial axis 28 is the axial centerline of rotation of the bicycle wheel 1. The hub flange 16 may be contiguous with the hub shell 14 or it may be separately formed and assembled to the hub body 12 portion of the hub shell 14. The spokes 2 are affixed to the hub flange 16 at their first end 4 and extend to attach the rim 8 at their second end 6. The tire 10 is fitted to the outer periphery of the rim 8. The wheel of FIG. 1 is generic and may be of tension-spoke or compression-spoke design.

The axial direction 92 is any direction parallel with the axial axis 28. The radial direction 93 is a direction generally perpendicular to the axial direction 92 and extending generally from the axial axis 28 radially outwardly toward the rim 8. The tangential direction 94 is a direction generally tangent to the rim at a given radius. The circumferential direction 95 is a cylindrical vector that wraps around the axial axis 28 at a given radius. A radial plane 96 is a plane perpendicular to the axial axis 28 that extends in a generally radial direction at a given axial intercept. An axial plane 97 is a plane that is generally parallel to the axial axis. An axially inboard orientation is an orientation that is axially proximal to the axial midpoint between the two end faces 11 a and 11 b. Conversely, an axially outboard orientation is an orientation that is axially distal to the axial midpoint between the two end faces 11 a and 11 b. An axially inwardly facing surface is a surface that faces toward the axial midpoint between the two end faces 11 a and 11 b. Conversely, an axially outwardly facing surface is a surface that faces away from the axial midpoint between the two end faces 11 a and 11 b. Similarly, an axially inward direction is a direction that extends toward the axial midpoint between the two end faces 11 a and 11 b. Conversely, an axially outward direction is a direction that extends away from the axial midpoint between the two end faces 11 a and 11 b. A radially inboard orientation is an orientation that is radially proximal to the axial axis 28 and a radially outboard orientation is an orientation that is radially distal to the axial axis 28. While it is most common for the hub shell 14 to rotate about a fixed axle 9, there are some cases where it is desirable to permit the axle 9 to be fixed with the wheel 1, such as the case where the wheel 1 is driven by the axle 9.

FIGS. 2 a, 2 b and 2 c describe the current technology in conventional bicycle wheels that most cyclists are familiar with. This prior art design includes a rim 8, a huh shell 14 and a plurality of spokes 2. The hub shell 14 is rotatable about the axle 9 and includes a pair of axially spaced hub flanges 16. The wheel is assembled by first threading each individual spoke 2 through an axial hole 17 in the hub flange 16 until the j-bend 19 is hooked within the hole 17. The spoke 2 is then pivoted to extend in a generally radial direction toward the rim 8. The enlarged portion 34 or “head” of the spoke 2 prevents the spoke 2 from pulling through the hole 17 in the hub flange 16. The second end 6 of each spoke 2 is then fixed to the rim 8 via spoke nipples 21. Tightening the threaded engagement between the spoke nipple 21 and the spoke 2 serves to effectively shorten the length of the spoke 2. Thus, as the nipples 21 are threadably tightened, the spokes are drawn up tight and a degree of pre-tension is induced in the spoke 2. By selectively adjusting this threaded engagement, the spoke pre-tension may be adjusted to align the trueness of the rim 8. The spoke pre-tension is resisted by circumferential compression of the rim 8 and it is this balance of forces that imparts efficient structural integrity to the bicycle wheel 1. Also shown in FIG. 2 b is bracing angle 38 between the radial centerline plane of the rim 8 and the tensile axis 36 of the spokes 2. As this bracing angle 38 is increased, the lateral stiffness (i.e. stiffness in the axial direction 92) of the wheel 1 is also increased.

FIG. 3 a shows prior art single-wall rim 18 with a single lower web or spoke bed 22 wall. Rim 18 includes two hooked flanges 26 a and 26 b for capturing the bead of a tire (not shown). Tire well 24 is a circumferential channel bounded by spoke bed 22 and flanges 26 a and 26 b. Spoke 2 includes threaded end 31 for threadable engagement with spoke nipple 21. Rim 18 may be produced as an aluminum extrusion that also includes cavities 29 a and 29 b to accept pins (not shown) that serve to join the butted ends of the extruded profile to create a continuous rim hoop. During assembly, the threaded end 31 of spoke 2 is first positioned to extend through the inside diameter end of opening 23. Next, the nipple 21 may be threadably assembled to the threaded end 31 of the spoke 2 through the outside diameter end of opening 23. With all of the spokes 2 of the wheel assembled to the rim 18 in this way, a completed wheel assembly 1 is achieved. A rim strip (not shown) is commonly utilized to cover the radial outboard surface of the spoke bed and to protect the inner tube (not shown) from damage.

FIG. 3 b shows a prior art rim 20 of double-wall configuration with an upper web or tire bed 32 wall and a lower web or spoke bed 33 wall. Rim 10 includes two hooked flanges 36 a and 36 b for capturing the bead of a tire (not shown). Tire well 24 is a circumferential channel bounded by tire bed 32 and flanges 36 a and 36 b. Spoke bed 33 includes opening 36 and tire bed 32 includes concentric opening 35, which serve to accept a spoke 2 and spoke nipple 21. Spoke 2 includes threaded end 31 for threadable engagement with spoke nipple 21. Rim 18 is produced as an aluminum extrusion that also includes an internal cavity 20 bounded by the spoke bed 33, the tire bed 32 and sides 25. It may be seen that, during assembly, the threaded end 31 of spoke 2 is first positioned to extend through the inside diameter end of opening 35. Next, the nipple 21 is threadably assembled to the threaded end 31 of the spoke 2 first through opening 35 and then through opening 36. With all of the spokes 2 of the wheel assembled to the rim in this manner, a completed wheel assembly is achieved. It may be seen that, with the nipple 21 bearing against the spoke bed 32, opening 35 remains exposed as a passageway between the tire well 24 and the cavity 20. A rim strip (not shown) is commonly utilized to cover the radial outboard surface of the spoke bed and to protect the inner tube (not shown) from damage.

FIG. 4 shows an exemplary bicycle wheel 319 that corresponds to some of the embodiments described herein. This figure is shown to provide a generic assembly to illustrate an arrangement wherein the present invention may be adapted to utilization in bicycle wheel construction. The bicycle wheel 319 includes spokes 100, rim 324, hub assembly 329 and tire 320. The hub assembly 329 includes hub shell 328, axle 322, axle caps 323 a and 323 b and bearings 321. The rim 324 includes tire bed 325 wall with geometry for mounting of a tire 320 and a spoke bed 326 wall with a multiplicity of spoke holes 330, each to accept an individual connector 66, and sidewalls 327 a and 327 b to define a cavity 331. Hub shell 328 includes a flange portions 332 a and 332 b, which each include a multiplicity of spoke holes 330, each to accept an individual connector 66.

It is noted that the rim 325 and hub shell 328 shown here are exemplary representations of a bracing element that may take on a wide range of forms. The spokes 100 are connected at their first end 103 to the hub shell 328 and at their second end 105 to the rim 324. Spokes 100 are connected to the rim 324 and hub shell 328 by means of sleeves 86 and connectors 66 as described in greater detail in FIGS. 5 a-i and other embodiments described herein. The spoke 100 is a generally long slender tensile element with a longitudinal axis 37 along its length and generally parallel to its sidewalls. The spoke 2 also has a tensile axis 36 of applied tensile load, which is generally collinear to the longitudinal axis 37. For the purposes of definition, the term “longitudinal” herein refers to alignment along the longitudinal axis. Further, the term “lateral”, as defined herein, refers to alignment and/or orientation in a direction that is generally orthogonal to the longitudinal axis 37. While the term “spoke bed” is commonly used in reference to the outer rim, as described herein, the term “spoke bed” may also refer to the portion of the hub shell to which the spoke is connected (i.e. flange portions 332 a and 332 b).

The connector 66 is generally shown to serve as a termination to the spoke 100 and provide means to connect or anchor the spoke 100 to a bracing element (i.e. rim 324 and/or hub shell 328). Note that the span of spoke 2 is aligned in the direction of spoke tension 30 and along the tensile axis 36, which extends through the longitudinal axis 37 of the spoke 100. It is shown here that several spokes 100 of the wheel 319 may be terminated in this manner. For simplicity in describing many of these embodiments, a rim connection arrangement is described, with the understanding that such an embodiment may be easily adapted to hub connections as well. It is understood that FIG. 4 corresponds to a simplified arrangement for illustration purposes. Several of the embodiments of the present invention may be applied to this arrangement, as well as arrangements which include facility for creating and/or adjusting spoke pre-tension, as described in FIGS. 5 a-i.

The present invention comprises a spoke (i.e. spoke 100), which may be considered as a longitudinal tensile element having an end portion and a cross-section thereof, a connecting element (i.e. connectors 66), a bracing element (i.e. hub shell 651 and rim 648), and a tensile axis of applied tensile load along the longitudinal tensile element. The spoke is connected to the connecting element by means of an overlie engagement and/or a longitudinal engagement between the spoke (and/or an intermediate element connected to the spoke) and the connecting element. In the embodiments shown herein, the longitudinal tensile element is a vehicle wheel spoke, the hub shell or hub flange constitutes a first bracing element and the outer rim constitutes a second bracing element.

A longitudinal tensile element (i.e. spoke) is a generally long slender element, with a length greater than its cross sectional width, and with a longitudinal axis 37 extending generally along its length. The spoke includes external sidewall surface(s) that extend generally along its length. As such, the longitudinal axis 37 is generally parallel to the sidewall surface. The tensile axis 36 is the axis along which tensile loads (i.e. spoke tension 30) are applied to the tensile element, and is commonly collinear with the longitudinal axis 37, particularly in the region of the structural span of the spoke. For the purposes of explanation herein, the term “longitudinal axis” is generally interchangeable with the term “tensile axis” unless otherwise noted. Some examples of a longitudinal tensile element include the spoke of a vehicle wheel, a guy wire, a control cable, or a tendon. In most of the embodiments of the present invention, the longitudinal tensile element is capable of supporting load in tension, otherwise known as positive tensile loading, along its length. However, the longitudinal tensile element may alternatively support load in compression along its length, otherwise known as negative tensile loading, where the longitudinal tensile element provides columnar support between two bracing elements. The spoke span is considered as the portion of the spoke that is under tension (or compression) and that extends between its anchor points and/or engagements at the bracing elements (i.e. hub and rim). A location outboard of the spoke span is a location along the tensile axis 36 that is beyond or external to the spoke span. Further, a longitudinally outward orientation refers to an orientation along the longitudinal axis that is distal from the midpoint of the span. Conversely a longitudinally inward orientation refers to an orientation along the longitudinal axis that is proximal to the midpoint of the span.

For the purposes of using conventional terminology, the term “hub flange” is used herein to describe a region of the hub shell to which the spokes are joined. While the surface of the hub flange may be raised and flange-like in comparison to other surfaces of the hub shell, this is not a requirement for the present invention and the hub flange may alternatively be flush or recessed relative to other hub shell surfaces. An overlie engagement between two elements is an engagement wherein a first element includes a laterally extending surface that extends generally laterally from the direction of load. This laterally extending surface overlaps or overlies a mating surface or edge of the second element such that the first element is engaged and connected to the second element in the direction of load. The overlie engagement is preferably capable of supporting this load and maintaining this connection.

It may be termed that a longitudinal engagement is an engagement that includes a continuous longitudinal engagement interface or an engagement that includes at least two engagement interface locations that are longitudinally spaced along the longitudinal axis of the spoke. It is generally desirable that the longitudinal length of such an engagement be greater than the cross-sectional thickness of the spoke to create an effective engagement. Obviously, increasing the length of engagement may serve to increase the interface surface area and may therefore increase the load carrying capacity of a corresponding joinder between the connector and the spoke. A threaded engagement, with its continuous helix of engagement along a longitudinal length, is considered to be a longitudinal engagement.

A bracing element is one that resists or braces against all or part of the load of a tensile element. In other words, in order for a tensile element (i.e. spoke) to maintain its tension (or compression) and remain a generally static structure, it must have a resisting or bracing element to bear against. Thus, the tensile element is generally anchored to two bracing elements and the tensile element thereby serves to connect the two bracing elements to each other. In an example where the tensile element is generally held in tension, such as the spoke of a tension-spoke vehicle wheel, a first bracing element could be the hub flange and a second bracing element could be the outer rim hoop. Similarly, in the case where the tensile element is generally held in compression, such as the spoke of a compression-spoke vehicle wheel, the bracing element is that element which the tensile element is pushed against.

The term “blind connection” or “blind engagement” is well known in industry and refers to a connection between a first and second element where the first element may be connected to the second element without necessarily requiring access to both sides of the second element. For example, in a blind connection, a spoke may be connected to a hole in a rim by manipulating the spoke (or a connector associated with the spoke) through the first end of the hole without requiring access to the opposite end of this hole. Such a blind connection is particularly useful when access to the opposite end of the hole is limited or restricted or when the opposite end of the hole is otherwise obscured. As an example relating to several of the embodiments of the present invention, a blind connection between the spoke and the spoke bed is shown to be achieved by means of access only to the opening of the hole at the inboard surface of the spoke bed and without requiring access to the outboard surface of the spoke bed. As such, the blind connection provided by the present invention is particularly advantageous since the connection between the spoke and the spoke bed may be achieved by means of assembly and manipulation only through the accessible exterior of the bracing element and does not require access to the inaccessible interior of the bracing element. Such a blind connection has particular utility in double-wall rims for tubeless tires where the tire bed wall May advantageously remain unpierced to provide effective sealing of the internal cavity of the tire. This unpierced tire bed wall serves to obscure the longitudinally outward end of the hole in the spoke bed.

FIGS. 5 a-i describe an embodiment illustrating a blind connection between the spoke and the rim, showing the rim 54, connector 66, sleeve 86 and spoke 100. Rim 54 includes a tire bed 58 wall and a spoke bed 56 wall, with a cavity 60 or radial gap therebetween. The tire bed 58 supports the tire (not shown) and the spoke bed 56 includes a radially outboard surface 59, a radially inboard surface 61. Spoke bed 56 also includes a hole 62 therethrough with hole sidewall 63 and circular diameter 64. Hole 62 extends along central axis 57, which is shown here to be generally radial in direction. Spoke bed 56 is shown in fragmentary view for illustration purposes and it is understood that spoke bed 56 constitutes a portion of the rim or hub flange to which the connector 66 is attached. The outboard surface 59 represents a longitudinally outward surface adjacent the longitudinally outward opening of hole 62. Similarly, the inboard surface 61 represents a longitudinally inward surface adjacent the longitudinally inward entrance or opening of hole 62. While these surfaces are shown to be generally flat, planar, and orthogonal to the central axis 57, this is merely a representative arrangement and these surfaces may incorporate a wide range of geometries, including curved geometry, stepped geometry, projecting surfaces, recessed surfaces, conical, spherical, etc.

Connector 66 includes a flange 68 and is bifurcated to include two prongs 70 a and 70 b. Prongs 70 a and 70 b each include associated collar portions 72 a and 72 b, enlarged portions 74 a and 74 b, ramped surfaces 75 a and 75 b and overhang surfaces 76 a and 76 b respectively. Slots 73 a and 73 b provide a gap between prongs 70 a and 70 b to provide clearance for their flexure. Slots 73 a and 73 b are shown to be generally tapered, with a larger width 80 adjacent enlarged portions 74 a and 74 b and a narrower width 87 at the root adjacent the flange 68. Collar portions 72 a and 72 b have a width 82 across their external surfaces and enlarged portions 74 a and 74 b have a width 84 across their outer surfaces, with overhang surfaces 76 a and 76 b having widths 83 a and 83 b respectively. The opening 77 extends along the opening axis 78 through the flange 68 and the prongs 70 a and 70 b. Opening 77 also includes internal threads 79 therethrough for threadable engagement with external threads 88. It may be seen that the flange 68 is hexagonal and noncircular and includes flats 71 such that it may be manually manipulated with a wrench (not shown). Flange 68 includes a longitudinally outward and laterally extending flange face 67 to interface with the inboard surface 61. Collar portions 72 a and 72 b are shown to extend between the flange face 67 and their respective overhang surfaces 76 a and 76 b. It is noted that prongs 70 a and 70 b have external geometry that is laterally distal from the opening axis 78, such as the collar portions 72 a and 72 b and overhanging surfaces 76 a and 76 b, and internal geometry, such as opening 77 and slots 73 a and 73 b.

Sleeve 86 includes external threads 88 to threadably mate with internal threads 79, longitudinal hole 90 therethrough, and countersink 91 to nest with transition surface 104. Sleeve also includes flats 89 such that it may be manually manipulated with a wrench (not shown). Spoke 100 includes a shank portion 101, an enlarged head 102 and a transition surface therebetween. The spoke 100 is shown in FIG. 5 a to be loosely preassembled to the sleeve 86, with the shank portion 101 extending through the hole 90 along the longitudinal axis 37.

As shown in FIG. 5 g, the connector 66 is first assembled to the rim 54 in direction 81 by pressing the ramped surfaces 75 a and 75 b into hole 62 such that the ramped surfaces 75 a and 75 b cam against the entrance to the hole 62 to flex the connector 66 and deflect prongs 70 a and 70 b in respective directions 85 a and 85 b toward each other and collapsing slots 73 a and 73 b and other internal surfaces. This flexure occurs within the prongs 70 a and 70 b and in the flange 68 adjacent the root of slots 73 a and 73 b, generally about a flexure axis 69 (as shown in FIG. 5 a) that is generally parallel to an axial plane 97. Thus, the connector 66 is flexed to achieve an unexpanded or collapsed orientation, with prongs 70 a and 70 b proximal to each other such that width 84 is reduced to allow the enlarged portions 74 a and 74 b to pass within the hole 62 as shown. It is preferable that this flexure or deformation occurs as elastic deformation of the connector 66, so that the connector 66 may spring back to its original expanded or open orientation. However, it is also permissible for some plastic deformation to occur, since the subsequent engagement with the sleeve 86 will still force the connector into its open orientation.

The connector 66 is further advanced in direction 81 until face 67 abuts inboard surface and 61 the overhang surfaces 76 a and 76 b are aligned with the outboard surface 59 of the spoke bed 56. The connector 66 then may spring back to its original expanded or open orientation as shown in FIGS. 5 d and 5 h with prongs 70 a and 70 b in their original distal orientation. The width 82 is now closely matched to the diameter 64 such that the collar portions 72 a and 72 b are nested within sidewall 63 to generally fill the hole 62. The overhang surfaces 76 a and 76 b now overlie the outboard surface 59 and retain the connector 66 within the hole 62 in an overlie engagement. The flange face 67 is now adjacent the inboard surface 61 of the spoke bed 56. Additionally, the width 99 of the flange 68 is shown to be larger than the diameter 64 of the hole 62, thus preventing the connector 66 from advancing too far in direction 81 and becoming disengaged with hole 72 and lost within the cavity 60. It is preferable that the overhang surfaces 76 a and 76 b be generally matched to the outboard surface 59 in a surface-to-surface overlie engagement. This maximizes the area of contact and minimizes the contact stress at this engagement interface. Alternatively, the overhang surfaces 76 a and 76 b may contact only an edge of the spoke bed 56, such as the longitudinally outward edge of the hole 62, in a surface-to-edge overlie engagement. Such an engagement has comparatively reduced contact area and results in higher contact stress.

Next, as shown in FIGS. 5 e and 5 i, sleeve 86 is fully threaded into opening 77, with external threads 88 threadably engaged to internal threads 79. The opening 77 of the connector 66 is now plugged and filled by the sleeve 86, thus providing a bridging or blocking engagement between the prongs 70 a and 70 b to limit the inward or laterally proximal movement of the prongs 70 a and 70 b and preventing the connector 66 from inadvertently achieving an unexpanded or collapsed orientation. The prongs 70 a and 70 b are now locked in their expanded or open and spread orientation. Thus, the overlie engagement between the overhang surfaces 76 a and 76 b and the outboard surface 59 is now maintained, thereby locking the connector 66 to the rim 54. Further, the sleeve 86 is now threadably engaged to the connector 66 in a longitudinal engagement that occurs over at least a portion of the longitudinal length of the opening 77. Finally, as spoke tension 30 is applied to the spoke 100, the spoke 100 is drawn longitudinally inwardly and the transition surface 104 is nested within the countersink 91 in an overlie engagement. Thus the spoke 100 is connected and engaged with the sleeve 86, which is connected and engaged to the connector 66, which is connected and engaged to the rim 54. It should be noted that the sleeve serves as an intermediate connecting element between the spoke 100 and the connector 66. These connections effectively join the spoke 100 to the rim 54 to resist spoke tension 30 along tensile axis 36. Thus, a blind connection between the spoke 100 and the spoke bed 56 is achieved. It may be seen that the present invention provides particular advantage in tubeless tire configurations, since the sealed tire bed 24 is not required to be pierced and may now be used as a sealing air barrier.

Since a portion of internal threads 79 extend longitudinally through the corresponding enlarged portions 74 a and 74 b, a portion of their threaded engagement with external threads 88 is shown to be longitudinally outward of the overhang surfaces 76 a and 76 b. Thus, a portion of the overlie engagement between the collar 86 and the connector 66 is longitudinally outward of the outboard surface 59 as well. This is preferable, since it serves to provide increased support and reduced stress in the connector 66.

Flange 68 preferably includes laterally projecting geometry that is sized to extend outside the perimeter of hole 62 and to laterally overlie the inboard surface 61 adjacent the entrance to hole 62. Thus, by contacting and abutting the inboard surface 61, the flange 68 may serve to provide a depth stop to the connector 66, limiting its advancement in respective direction 81 during assembly to insure proper alignment between overhang surfaces 76 a and 76 b and outboard surface 59. Further, the overlie of the flange face 67 with the inboard surface 61 may serve to retain the connector 66 to the hole 62, thus preventing the connector 66 from inadvertently advancing too far beyond the outboard surface 59 and potentially becoming lost and disengaged with the cavity 60. While flange 68 provides the convenience of a depth stop and provides the convenience for manual manipulation as described, it is understood that these functions may not be critical for proper function of the connector 66 and that flange 68 may alternatively be omitted and/or may have an alternate geometry form.

The spoke tension 30 pre-load may be adjusted as previously described by threadably adjusting the external threads 88 relative to the internal threads 79 by means of a wrench (not shown) engaged to flats 89. Further, the connector 66 may be prevented from inadvertently rotating during this adjustment by means of a wrench (not shown) engaged with flats 71. The spoke 100 and connector 66 may be disassembled in the reverse of the assembly steps just described. First, the sleeve 86 is unscrewed and withdrawn from the connector 66 such that is no longer providing a blocking engagement between prongs 70 a and 70 b. Second, the connector 66 may be collapsed and withdrawn from hole 62 in a longitudinally inward direction opposite direction 81.

Since light weight and ductility of the connector 66 are desirable attributes, it is preferable that the connector be formed from a polymeric material, such as an engineering thermoplastic, or from a light metal, such as aluminum. However a wide range of materials may be utilized to produce the connector 66.

FIG. 5 j corresponds to the view of FIG. 5 f and describes a connector 106 similar to connector 66 in all respects, except that the opening 108 is not fully threaded along its entire length and includes an unthreaded portion 109 as well as an internally threaded portion 111. Connector 106 includes flange 114 and prongs 107 a and 107 b with enlarged portions 112 a and 112 b and collar portions 113 a and 113 b respectively. The connector 106 may alternatively be substituted for connector 66 in FIGS. 5 a-i. It is preferable that the diameter 110 of the unthreaded portion 109 be sized for a close fit with the outside diameter of the external threads (not shown) of a mating element, such as a sleeve 86 (not shown). It is noted that the internally threaded portion 111 is longitudinally aligned with enlarged portions 112 a and 112 b as it may be preferable to provide a blocking engagement to provide support between prongs 112 a and 112 b in this region. The internally threaded portion 111 may provide a longitudinal engagement that occurs over a portion of the longitudinal length of the opening 108. Alternatively, it may be preferable that the threaded portion be longitudinally aligned with the flange and the unthreaded portion be longitudinally aligned with the flange. As a further alternative, various other threaded/unthreaded arrangements are possible.

FIGS. 5 k-L describes a connector 116 similar to connector 66 in all respects, except that the sidewall 120 of hole 118 is generally smooth and without fully formed threads. Connector 116 includes flange 121 and prongs 119 a and 119 b with enlarged portions 117 a and 117 b and collar portions 123 a and 123 b respectively. The connector 116 may alternatively be substituted for connector 66 in FIGS. 5 a-i. It is preferable that the diameter 122 of hole 118 be sized at approximately the pitch diameter of the external threads (not shown) of a mating element, such as a sleeve 86. When the sleeve 86 is forcibly threaded and introduced to hole 118, as shown in FIG. 5L, the cylindrical sidewalls 120 of the hole 118 are at least partially deformed to conform to the contour of the external threads 88 to create internal thread portions 124 a and 124 b in a thread-forming or self-tapping engagement that is well known in industry. It is noted that, in a molding operation to produce the connector 116, the lack of internal threads of the connector 116 make its molding less complex and costly as compared to connector 66 b, which includes pre-formed threads. Alternatively, internal thread portions 124 a and 124 b may be formed in a conventional tapping operation subsequent to the installation of connector 116 and prior to threadable assembly with the sleeve 86.

FIG. 5 m describes a connector 334 similar to connector 66 in most respects, except that the connector 334 includes three prongs 338 a, 338 b, and 338 c, which include collar portions 344 a, 344 b and 334 c respectively, enlarged portions 340 a, 340 b and 340 c respectively, overhang surfaces 342 a, 342 b and 342 c respectively, and slots 346 a, 346 b and 346 c. Connector 334 also includes flange 335 and opening 336 with internal threads 337. The connector 334 may alternatively be substituted for connector 66 in FIGS. 5 a-i. This embodiment is representative of a range in quantity and configurations of prongs that may be alternatively incorporated into the present invention.

FIG. 5 n describes a connector 348 identical to connector 66 as shown in FIG. 5 a-i with the exception that the overhang surfaces 351 a and 351 b are angled and non-planar. FIG. 5 n corresponds to the view of FIG. 5 h. Connector 348 includes flange 353 and prongs 349 a and 349 b with enlarged portions 350 a and 350 b, overhang surfaces 351 a and 351 b, and collar portions 352 a and 352 b respectively. Overhang surfaces 351 a and 351 b are shown to be generally conical at angle 355 to the central axis 57 of the hole 62 of spoke bed 56 which is less than 90 degrees. This angle allows the overhang surfaces 352 a and 351 b to wedge the outboard surface 59 adjacent the hole 62 as shown.

The embodiment of FIGS. 6 a-e is similar to the embodiment of FIGS. 5 a-i. However, while FIGS. 5 a-i shows a circular hole 62, FIGS. 6 a-e describe an exemplary embodiment where the hole 131 of spoke bed 127 is non-circular and may provide a keyed engagement with the collar portion 143 a and 143 b of the connector 137. Also, while FIGS. 5 a-i show the hole axis 57 to be generally parallel and collinear with the opening axis 78, FIGS. 6 a-e shows an angle 160 between the central axis 133 and the opening axis 151. Spoke bed 127 is shown in fragmentary view for illustration purposes and it is understood that spoke bed 127 constitutes a portion of the rim or hub flange to which the connector 137 is attached. Spoke bed 127 includes an outboard surface 128, an inboard surface 129 and a hole 131 therethrough with hole sidewall 132. Hole 131 has a generally oval profile, with a length 134 greater than its width 138 and is noncircular, including flats 135. While this oval hole profile is merely representative of a wide range of possible noncircular hole profiles, the oval profile may be particularly preferable since it may be produced in a simple milling operation. Hole 131 extends along central axis 133 and has a width 138.

Connector 137 includes a flange 139 and is bifurcated to include two prongs 140 a and 140 b. Prongs 140 a and 140 b each include associated collar portions 143 a and 143 b, enlarged portions 145 a and 145 b, ramped surfaces 146 a and 146 b and overhang surfaces 148 a and 148 b respectively. Slots 144 a and 144 b provide the requisite gap between prongs 140 a and 140 b and are shown to taper inward toward the flange 139 similar to that described in FIGS. 5 a-i. Collar portions 143 a and 143 b have a width 155 across their external surfaces and enlarged portions 145 a and 145 b have a width 157 across their outer surfaces, with overhang surfaces 148 a and 148 b having widths 156 a and 156 b respectively. The Opening 150 extends along the central axis 133 through the flange 139 and the prongs 140 a and 140 b. Opening 150 also includes internal threads 152 therethrough for threadable engagement with external threads 88. It may be seen that the flange 139 is noncircular and includes flats 141 such that it may be manually manipulated with a wrench (not shown). Slots 144 a and 144 b are shown to be tapered, with a larger width at the opening adjacent the enlarged portions 145 a and 145 b and narrower width at the root adjacent the flange 139. Collar portions 143 a and 143 b are shown to extend between the flange 139 and their respective overhang surfaces 148 a and 148 b. Sleeve 86 and spoke 100 are identical to those described in FIGS. 5 a-i.

As shown in FIG. 6 d, the connector 137 is assembled to the spoke bed 127 in direction 154 in a manner similar to that previously described in FIGS. 5 g-h. Thus, the connector 137 is flexed to achieve a collapsed orientation such that width 157 is reduced to allow the enlarged portions 145 a and 145 b to pass through the hole 131.

As the connector 137 is further advanced in direction 154, the overhang surfaces 148 a and 148 b align with the outboard surface 128 of the spoke bed 127 and the connector springs back to its original open orientation as shown in FIG. 6 d. The width 155 is now closely matched to the length 134 such that the collar portions 143 a and 143 b generally fill the hole 131. The overhang surfaces 148 a and 148 b now overlie the outboard surface 128 and retain the connector 137 within the hole 131. The flange 139 is now also adjoining the inboard surface 129 of the spoke bed 127 and is functional in a manner similar to that described in FIGS. 5 a-i.

Next, as shown in FIG. 6 e, sleeve 86 is fully threaded into opening 150, with external threads 88 threadably engaged to internal threads 152 in a manner similar to that described in FIGS. 5 e and 5 i, thus locking the prongs 140 a and 140 b in their open and spread orientation and preventing the connector 137 from achieving a collapsed orientation, thereby locking the connector 137 to the spoke bed 127. As previously described, the spoke 100 is connected and engaged with the sleeve 86, which is connected and engaged to the connector 137, which is connected and engaged to the spoke bed 127. It should be noted that the sleeve 86 serves as an intermediate connecting element between the spoke 100 and the connector 137. These connections effectively join the spoke 100 to the spoke bed 127 to resist spoke tension 30 along tensile axis 36. The spoke tension 30 pre-load may also be adjusted as previously described.

The embodiment of FIGS. 7 a-c is similar to the embodiment of FIGS. 5 a-i. However, while the inboard surface 61 and outboard surface 59 are shown to be relatively flat, the inboard surface 166 and outboard surface 167 of spoke bed 164 of FIGS. 7 a-b is shown to include surface projections 169 a, 169 b, 171 a and 171 b adjacent hole 173 that may engage the notches 189 a, 189 b, 190 a and 190 b in the connector 175. Spoke bed 164 is shown in fragmentary view for illustration purposes and it is understood that spoke bed 164 constitutes a portion of the rim or hub flange to which the connector 175 is attached. Spoke bed 164 includes an outboard surface 167 with projections 171 a and 171 b, an inboard surface 166 with projections 169 a and 169 b and a circular hole 150 therethrough. Hole 131 extends along central axis 133.

As shown in FIGS. 7 a and 7 b, connector 175 includes a flange 186 and is bifurcated to include two prongs 187 a and 187 b. Prongs 187 a and 187 b each include associated collar portions 176 a and 176 b, enlarged portions 180 a and 180 b and overhang surfaces 183 a and 183 b respectively. Slots 178 a and 178 b provide the requisite gap between prongs 187 a and 187 b. Flange 186 includes notches 190 a and 190 b (obscured). Enlarged portions 180 a and 180 b include notches 189 a and 189 b (obscured) respectively. The opening 184 extends along the opening axis 191. Opening 184 also includes internal threads 193 therethrough for threadable engagement with external threads 88 of a sleeve 86 (not shown) as previously described. Sleeve 86 and spoke 100 are identical to those described in FIGS. 5 a-i.

Next, as shown in FIG. 7 c, the connector 175 is assembled to the spoke bed 164 in direction 194 as previously described in FIGS. 5 a-i, with overhang surfaces 183 a and 183 b in an overlie engagement with the outboard surface 167 of the spoke bed 164. It is noted that the notches 189 a and 189 b are now interlocked and engaged with projections 171 a and 171 b respectively. Similarly, notches 190 a and 190 b are now interlocked and engaged with projections 169 a and 169 b respectively. These engagements serve to key the connector 175 to the spoke bed 164 to limit relative rotation between the two about the central axis 133. Finally, a sleeve 86 (not shown) is fully threaded into opening 184, with external threads 88 (not shown) threadably engaged to internal threads 193 in a manner previously described to lock the connector 175 to the spoke bed 165 and to join the spoke (not shown) to the connector 175.

The embodiment of FIGS. 8 a-c is similar to the embodiment of FIGS. 5 a-i. However. while FIGS. 5 a-i shows relatively flat inboard surface 61 and outboard surface 59. the spoke bed 197 of FIGS. 8 a-c shows a curved or contoured inboard surface 199 and a curved or contoured outboard surface 200 of spoke bed 197. Further, while central axis 57 of hole 62 is shown to extend generally radially, FIGS. 8 a-c shows the central axis 202 of hole 208 to be drilled at an angle 204 to a radial vector 205. Such an angle 204 may accommodate a bracing angle 38, as described in FIG. 2 b. Still further, while the connector 66 is not shown to be rotationally keyed to the spoke bed 56, FIGS. 8 a-c shows the curved and contoured outboard surface 200 to be nested and matched to similarly contoured overhang surfaces 216 a and 216 b and the contoured inboard surface 199 to be nested and matched to a similarly contoured outward face 221 of flange 220. These matched surfaces serve to limit relative rotation between the connector 210 and the rim 196 about the central axis 202.

As shown in FIGS. 8 a and 8 c, rim 196 includes a tire bed 201, a spoke bed 197 and a cavity 203 therebetween. Tire bed 201 includes a radially outboard surface 200, a radially inboard surface 199 and a hole 208 extending along central axis 202 therethrough with sidewall 209. Hole 208 is shown to be drilled at an angle, with the central axis 202 at angle 204 with a radial vector 205. Outboard surface 200 has a concave curved surface as shown and inboard surface 199 has a curved convex surface as shown.

As shown in FIGS. 8 a and 8 c, connector 210 includes a flange 220 with an outward face 221 and is bifurcated to include two prongs 223 a and 223 b. Prongs 223 a and 223 b each include associated collar portions 212 a and 212 b, enlarged portions 214 a and 214 b and overhang surfaces 216 a and 216 b respectively. Outward face 221 is curved and generally saddle-shaped to provide a matched contour with inboard surface 199 of the spoke bed 197. Additionally, overhang surfaces 216 a and 216 b also define a curved and generally saddle-shaped contour that is matched with the inboard surface 199 of the spoke bed 197. Slots 213 a and 214 b provide the requisite gap between prongs 223 a and 223 b and are shown to taper toward the flange 220. The opening 218 extends along the opening axis 225 through the flange 220 and the prongs 223 a and 223 b and includes internal threads 226 therethrough for threadable engagement with external threads 88 of sleeve 86. Sleeve 86 and spoke 100 are identical to those described in FIGS. 5 a-i.

As shown in FIG. 8 c, the connector 210 is assembled to the spoke bed 197 in direction 227 in a manner similar to that previously described in FIGS. 5 g-h. As the connector 210 is advanced in direction 227, the overhang surfaces 216 a and 216 b align with the outboard surface 200 of the spoke bed 197 and the connector 210 springs back to its original open orientation as shown in FIG. 8 c. The curved overhang surfaces 216 a and 216 b are now nested with the curved outboard surface 200. Additionally, the curved outboard surface 221 is now nested with the curved inboard surface 199. Both nested surface interfaces provide a rotational interlock and serve to prevent the connector 210 from rotating about the central axis 202 relative to the spoke bed 197. The overhang surfaces 216 a and 216 b now overlie the outboard surface 200 as previously described and retain the connector 210 within the hole 208. As shown in FIGS. 8 a-c, central axis 202 is generally collinear with opening axis 225, thus opening 218 is also at angle 204 with radial vector 205.

Next, sleeve 86 may be advanced in direction 228 and fully threaded into opening 218, with external threads 88 threadably engaged to internal threads 226 in a manner similar to that described in FIGS. 5 e and 5 i, thus locking the prongs 223 a and 223 b in their open and spread orientation and preventing the connector 210 from achieving a collapsed orientation, thereby locking the connector 210 to the spoke bed 197. As previously described, the spoke 100 is connected and engaged with the sleeve 86, which is connected and engaged to the connector 210, which is connected and engaged to the spoke bed 197. These connections effectively join the spoke 100 to the spoke bed 197 to resist spoke tension forces along the tensile axis. The sleeve 86 serves as an intermediate connecting element between the spoke 100 and the connector 210. It is noted that the spoke 100 extends toward the hub flange (not shown) at angle 204 that preferably corresponds to the bracing angle.

FIGS. 9 a-d detail a connector 260 very similar to connector 66 of FIGS. 5 a-i, however connector 260 does not include a flange. Spoke bed 253 is shown in fragmentary view for illustration purposes and it is understood that spoke bed 253 constitutes a portion of the rim or hub flange to which the connector 250 is attached. Spoke bed 253 includes an outboard surface 255, an inboard surface 254 and a hole 256 therethrough with hole sidewall 258.

Connector 260 includes a cylindrical base portion 266 and is bifurcated to include two prongs 261 a and 261 b. Base portion 266 is the region where the two prongs 261 a and 261 b are joined and is sized to pass through the hole 256. Prongs 261 a and 261 b each include associated collar portions 262 a and 262 b, enlarged portions 264 a and 264 b and overhang surfaces 265 a and 265 b respectively. Slots 263 a and 263 b provide the requisite gap between prongs 261 a and 261 b, permitting proximal flex therebetween. The opening 267 extends along the central axis 268 through the base portion 266 and the prongs 261 a and 261 b. Opening 267 includes internal threads 268 and extends through the base portion 266 and prongs 261 a and 261 b. Internal threads 268 provide threadable engagement with external threads 277 of sleeve 276. Sleeve 276 includes external threads 277 to threadably mate with internal threads 268, longitudinal hole 279 therethrough, and internal threads 278 to mate with external threads 395 of spoke 394. Sleeve 276 also includes flats 280 such that it may be manually manipulated with a wrench (not shown). Spoke 394 includes an end portion 396 with external threads 395 to threadably mate with internal threads internal threads 278. The spoke 394 is shown in FIGS. 9 a-d to be loosely preassembled to the sleeve 276, with external threads 395 threadably mated with internal threads 278 along the longitudinal axis 37.

As shown in FIG. 9 b, the connector 260 is assembled to the spoke bed 253 in direction 270 in a manner similar to that previously described in FIGS. 5 g-h. Overhang surfaces 265 a and 265 b now overlie the outboard surface 255 in an overlie engagement as previously described to retain the connector 260 within the hole 256. Next, external threads 277 of sleeve 276 are threaded into opening 267 as shown in FIGS. 9 c-d, with external threads 277 threadably engaged to internal threads 268 in a manner similar to that described in FIGS. 5 e and 5 i, thus providing a lateral blocking engagement between prongs 261 a and 261 b and locking them in their open and spread orientation. This blocking engagement serves to prevent the connector 260 from achieving a collapsed orientation, thereby locking the connector 260 to the spoke bed 253. As previously described, the spoke 394 is connected and engaged with the sleeve 276, which is connected and engaged to the connector 260, which is connected and engaged to the spoke bed 253. These connections effectively join the spoke 100 to the spoke bed 253. The sleeve 276 serves as an intermediate connecting element to connect the spoke 394 to the connector 260.

This threaded connection between spoke 394 and sleeve 286 is representative of an alternate means to join the spoke and sleeve of many of the embodiments of the present invention that utilize a sleeve or other intermediate connecting element. It is understood that this threaded connection between spoke 394 and sleeve 286 is representative of a longitudinal engagement. Other longitudinal engagements may be substituted, such a s a crimped or knurled engagement where the spoke 394 has a configured surface that engages the hole 279 or vice versa. Further, it is anticipated that an integral joinder may be substituted for this threaded connection. Some examples of such an integral joinder include an adhesively bonded assembly, a brazed assembly, or a welded assembly.

FIG. 9 e describes an alternate embodiment similar to the embodiment of FIGS. 9 a-d, however intermediate connecting element is eliminated and the spoke 283 is shown to be threadably connected directly to the connector 260. Spoke bed 253 and connector 260 are identical to that described in FIGS. 9 a-d. Spoke 283 includes a threaded end 284 with external threads 285. The spoke 283 is shown to be threadably engaged to the connector 260, with external threads 285 engaged to internal threads 268. This threaded connection is representative of an alternate arrangement where the spoke is directly joined to the connector, thus eliminating the necessity of a sleeve or intermediate connecting element. This alternate arrangement may be substituted in many of the embodiments of the present invention that utilize a sleeve or intermediate connecting element.

FIGS. 10 a-c detail a connector 238 very similar to connector 66 of FIGS. 5 a-i. however connector 238 includes a radially outboard extension 250 that circumscribes opening 245. Spoke bed 230 is shown in cross-section fragmentary view for illustration purposes and it is understood that spoke bed 230 constitutes a portion of the rim or hub flange to which the connector 238 is attached. Spoke bed 230 includes an outboard surface 232, an inboard surface 231 and a hole 235 therethrough.

Connector 238 includes a flange 247 and is bifurcated to include two prongs 248 a and 248 b. Prongs 248 a and 248 b each include associated collar portions 240 a and 240 b, enlarged portions 242 a and 242 b and overhang surfaces 243 a and 243 b respectively. Prong 248 a also includes a collar extension 250 that circumferentially surrounds the opening 245 longitudinally outwardly from the overhang surface 243 a as shown. Slot 241 provides the requisite gap between prongs 248 a and 248 b to permit prongs to temporarily collapse during assembly with the spoke bed. The opening 245 extends along the central axis 225 through the flange 247 and the prongs 248 a and 248 b. Opening 245 includes internal threads 246 and extends through the flange 247, prongs 248 a and 248 b and extension 250. Internal threads 246 may threadable engagement with external threads 88 of sleeve 86. Sleeve 86 and spoke 100 are identical to those described in FIGS. 5 a-i. The connector 238 may alternatively be substituted for connector 66 in FIGS. 5 a-i.

As shown in FIG. 10 a, sleeve 86 may be is fully threaded into opening 245, with external threads 88 threadably engaged to internal threads 246 in a manner similar to that described in FIGS. 5 e and 5 i, thus plugging opening 245 and providing a lateral blocking engagement between prongs 248 a and 248 b to maintain their open and spread orientation and preventing the connector 238 from achieving a collapsed orientation, thereby locking the connector 238 to the spoke bed 230. As previously described, the spoke 100 is connected and engaged with the sleeve 86, which is connected and engaged to the connector 238, which is connected and engaged to the spoke bed 230. These connections effectively join the spoke 100 to the spoke bed 230. It is noted that the internal threads 246 associated with the collar 238 may provide increased length of thread engagement between the connector 238 and the sleeve 86. Further, the collar 238 may provide a full circumference of thread engagement to surround the sleeve 86.

The connectors of the previous embodiments are shown to be “normally open” and expanded in their relaxed state, with the prongs in a laterally spread or distal orientation. These connectors are pressed into their respective holes or are otherwise collapsed to the point where the enlarged portion may pass through the hole. Alternatively, the connector may be “normally closed” such that it is collapsed in its relaxed state, with the prongs in a laterally proximal orientation as shown in the embodiment of FIGS. 11 a-c. Otherwise, the embodiment of FIGS. 11 a-c is similar to the embodiment of FIGS. 5 a-i. Rim 293 includes spoke bed 294 wall with a radially outboard surface 295, a radially inboard surface 296 and a hole 297 of width 311 therethrough.

Connector 300 is shown in FIGS. 11 a-b in its relaxed state and includes a flange 306 and is bifurcated to include two prongs 301 a and 301 b. Prongs 301 a and 301 b each include associated collar portions 302 a and 302 b, enlarged portions 304 a and 304 b and overhang surfaces 305 a and 305 b respectively. Slots 303 a and 303 b (obscured in FIG. 11 c) between prongs 301 a and 301 b are shown as closed, with prongs 301 a and 301 b collapsed toward each other such that the width 313 generally corresponds to width 311. The opening 307 includes internal threads 308 and extends along the opening axis 309 through flange 306 and the prongs 301 a and 301 b. Internal threads 308 are shown in their relaxed state to be tapered as shown and serve to provide threadable engagement with external threads 88 of sleeve 86. Sleeve 86 and spoke 100 are identical to those described in FIGS. 5 a-i. The connector 300 may alternatively be substituted for connector 66 in FIGS. 5 a-i.

As shown in FIG. 11 b, the connector 300 is assembled to the spoke bed 294 in direction 310 such that connector 300 enters hole 297. It should be noted that, since the prongs 301 a and 301 b are already collapsed toward each other, the width 313 is sized to correspond to width 311 and the enlarged portions 304 a and 304 b may easily pass through the hole 297 without significantly flexing or deforming the connector 300. With the connector 300 fully advanced through the hole 297, the sleeve 86 is then threaded into the flange 306 end of the opening 307, with external threads 88 threadably engaging internal threads 308, as shown in FIG. 11 c and as previously described in FIGS. 5 a-i. As the sleeve 86 is further threaded into opening 307, the external threads 88 force the tapered internal threads 308 to expand to a straight and non-tapered threaded configuration, thus forcing the prongs 301 a and 301 b to spread in directions 315 a and 315 b. Thus, the width 313 across the enlarged portions 304 a and 304 b increases correspondingly and overhanging surfaces 305 a and 305 b now overlie the outboard surface 295, resulting in an overlie engagement to lock the connector 300 to the rim 293 as previously described in FIGS. 5 a-i. With sleeve 86 positioned in opening 307 between prongs 301 a and 301 b, these prongs 301 a and 301 b are now locked in their spread, distal and expanded orientation, thus preventing the prongs 301 a and 301 b from inadvertently collapsing. As previously described, the spoke 100 is connected and engaged with the sleeve 86, which is connected and engaged to the connector 300, which is connected and engaged to the rim 293. These connections effectively join the spoke 100 to the spoke bed 253.

While my above description contains many specificities, these should not be construed as limitations on the scope of the invention, but rather as exemplifications of embodiments thereof. It is to be understood that the invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the invention, and which are susceptible of modification of form, size, and arrangement of parts and details of operation. For example:

While it is shown in many of these figures that the opening axis of the opening of the connector is generally collinear with the central axis of the corresponding hole in the spoke bed, the opening axis may alternatively be offset or may be angular with respect to the central axis of the corresponding hole. Further, while it is shown in many of these figures that the central axis of the opening of the connector is generally collinear with the tensile axis of the spoke span, the central axis of the opening may alternatively be at an angle to the tensile axis. In such a case, the spoke may be bent or deflected such that its longitudinal axis is aligned with the opening.

The sleeve may be regarded as an intermediate component in the connection between the spoke and the ferrule. In other words, the spoke connects to the sleeve, the sleeve connects to the connector, and the connector connects to the rim or hub. There may be additional intermediate components inserted in this chain of connection.

These figures show the connector component to include a flange located externally to the hole to which the connector is assembled. Such a flange may be useful in creating an external overlie engagement with the inboard surface of the spoke bed to control positioning of the connector and also prevent the connector from inadvertently being pushed completely through the hole. However, it should be recognized that the primary engagement of the present invention is the engagement to resist spoke tension, which is in the opposite direction to the overlie engagement of the flange. Therefore, the flange may provide a desirable convenience to aid in the assembly and/or retention of the ferrule but may not be a requirement for proper function of some or all of the embodiments described herein. The present invention may still be functional without an external flange of the connector.

The connector component may remain stationary with respect to spoke bed, while the sleeve and/or the spoke may be rotated about the axis of the spoke. Alternatively, the connector component may be permitted to rotate independently of the spoke bed. If desired, this would allow the connector to rotate and slip at its interface with the spoke bed.

The embodiments described herein show the spoke as connected to the connector via a connection between the spoke and both prongs of the connector. However it is envisioned that the spoke may alternatively be connected to only one of the prongs and not connected to another of the prongs.

The embodiments described herein show a blind connection with a blind hole through which the connector is connected. However the present invention may prove to be advantageous to achieve such a blind connection even in arrangements where the hole itself is not a blind hole and there is access to both ends of the hole.

While the embodiments described herein show a surface-to-surface overlie engagement between a surface of the spoke and a surface of the connector, it is also envisioned that this overlie engagement may include a surface-to-edge engagement, where the spoke or the connector includes an engagement edge that has an overlie engagement with a surface of the other of the spoke or connector.

The embodiments described herein show each prong of the connector to include an overhang surface to engage the spoke bed. Alternatively, one (or more) of the prongs may not include an enlarged portion and/or an overhang surface to engage the spoke bed. However, at least one of the prongs must include the requisite overhang surface to engage the spoke bed. Further, many of the embodiments described herein show a connector with all of its overhang surfaces coinciding with a generally common plane. It is envisioned that the multiple overhang surfaces of a single connector may be offset from each other along the longitudinal axis and may correspond to different longitudinal heights.

Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but is instead intended to encompass all such modifications that are within its spirit and scope as defined by the claims. 

1. A vehicle wheel, comprising: a peripheral wheel rim; a central hub with a central axle and an outer flange; a plurality of spokes extending between said peripheral rim and said central hub with a first portion connected to said rim and a second portion opposed to said first portion and connected to said hub and a span portion between said rim and said hub, wherein said spoke is a generally slender element with a length greater than its width and longitudinal axis along said length and a tensile axis of applied tensile load along said span portion; a bracing element including a hole therein with a central axis, a hole sidewall, a longitudinally inward entrance, and at least one of an engagement surface and an engagement edge adjacent said hole and longitudinally outward of said entrance, wherein said bracing element comprises at least a portion of at least one of said rim and hub; a connecting element connected to said bracing element, including a collar portion, a central opening extending along an opening axis, and a multiplicity of prong portions to include a first prong and a second prong; wherein at least one of said first prong and said second prong includes an enlarged portion and a generally laterally projecting overhang surface; wherein said connecting element is a resilient element that may be flexed between a collapsed orientation wherein said enlarged portion of said first prong is proximal to said second prong and an expanded orientation wherein said enlarged portion of said first prong is distal to said second prong; wherein said connecting element is positioned within said hole, with said collar portion extending to overlap said hole sidewall along said central axis and with said overhang surface laterally overlying at least one of said engagement surface and said engagement edge in an overlie engagement; wherein said spoke is connected to said connecting element by means of a threaded engagement with said central opening; wherein said enlarged portion may be fitted within said hole in said collapsed orientation; and wherein said overlie engagement supports said tensile load.
 2. A wheel according to claim 1, wherein said hole is a blind hole, where said hole is obscured longitudinally outwardly from said at least one of said engagement surface and said engagement edge.
 3. A wheel according to claim 1, wherein said bracing element is said rim, including a spoke bed wall and a tire bed wall, wherein said spoke hole extends within said spoke bed wall and said tire bed wall serves to obscure said hole longitudinally outwardly from said at least one of said engagement surface and said engagement edge.
 4. A wheel according to claim 1, wherein said spoke, or an intermediate element connected to said spoke, serves to provide a blocking engagement between said first prong and said second prong to limit proximal movement of said first prong in a direction lateral to said opening axis and to maintain a said overlie engagement.
 5. A wheel according to claim 1, wherein said spoke, or an intermediate element connected to said spoke, includes external threads and wherein said central opening includes pre-formed internal threads and wherein said threaded engagement includes threadable engagement between said external threads and said internal threads.
 6. A wheel according to claim 1, wherein said spoke, or an intermediate element connected to said spoke, includes external threads and wherein said wherein said threaded engagement includes a threadable engagement between said external threads and said central opening in a self-tapping threaded engagement.
 7. A wheel according to claim 5, wherein said internal threads extend the full longitudinal length of said central opening.
 8. A wheel according to claim 5, wherein said internal threads extend along only a portion of the full longitudinal length of said central opening.
 9. A wheel according to claim 1, wherein said spoke is directly connected to said connecting element.
 10. A wheel according to claim 1, including an intermediate connecting element, wherein said spoke is connected to said intermediate connecting element and said intermediate connecting element is connected to said connecting element.
 11. A wheel according to claim 10, wherein said intermediate connecting element includes a non-circular portion to facilitate manual manipulation of said intermediate connecting element relative to said bracing element.
 12. A wheel according to claim 1, wherein said connecting element has a rotationally keyed engagement with said bracing element to limit relative rotation therebetween about said central axis.
 13. A wheel according to claim 1, wherein said bracing element is said rim, including a spoke bed wall, wherein said hole is in said spoke bed wall.
 14. A wheel according to claim 1, wherein said bracing element is said hub and wherein said hole is in said outer flange.
 15. A wheel according to claim 1, wherein said hole of said bracing element is a circular hole.
 16. A wheel according to claim 1, wherein said hole of said bracing element is a non-circular hole.
 17. A wheel according to claim 16, wherein said connecting element includes geometry to engage the sidewall of said non-circular hole to limit rotation of said connecting element relative to said bracing element about said central axis.
 18. A wheel according to claim 1, wherein said connecting element includes a flange portion longitudinally inward of said entrance.
 19. A wheel according to claim 15, wherein said flange portion includes a laterally projecting surface that extends laterally outward of said entrance.
 20. A wheel according to claim 15, wherein said flange portion includes a non-circular portion to facilitate manual manipulation of said connecting element about said central axis.
 21. A wheel according to claim, wherein said flange portion provides a depth stop to limit the longitudinally outward advancement of said connecting element within said hole.
 22. A wheel according to claim 1, wherein said multiplicity of said prongs constitutes two prongs.
 23. A wheel according to claim 1, wherein said multiplicity of said prongs constitutes three or more prongs.
 24. A wheel according to claim 1, wherein said central axis and said opening axis are generally collinear.
 25. A wheel according to claim 1, wherein said central axis and said opening axis are generally offset.
 26. A wheel according to claim 1, wherein said central axis and said central opening axis are generally non-parallel, with an angle therebetween.
 27. A wheel according to claim 1, wherein said wheel is a tension spoke wheel including pre-tensioned spokes.
 28. A wheel according to claim 1, wherein said connecting element may be flexed between said unexpanded position and said expanded position with an axis of flexure that is generally parallel to an axial plane.
 29. A wheel according to claim 1, wherein said connecting element may be flexed between said unexpanded position and said expanded position with an axis of flexure that is generally perpendicular to an axial plane.
 30. A wheel according to claim 1, including an intermediate connecting element, wherein said spoke is connected to said intermediate connecting element at a first connection and said intermediate connecting element is connected to said connecting element at a second connection, and wherein said intermediate connecting element includes said external threads for said threaded engagement with said opening.
 31. A wheel according to claim 30, wherein said intermediate connecting element includes a cavity to receive said spoke, and wherein said cavity includes internal threads, and wherein said spoke includes external threads for threaded engagement with said internal threads of said cavity.
 32. A wheel according to claim 30, wherein said intermediate connecting element includes a cavity to receive said spoke and an engagement surface adjacent said cavity and wherein said spoke includes a laterally projecting transition surface and wherein said spoke is connected to said intermediate connecting element by means of an overlie engagement between said transition surface and said engagement surface to resist spoke tension forces.
 33. A wheel according to claim 1, wherein said overlie engagement is a surface-to-surface overlie engagement between the generally matched surfaces of said overhang surface and said engagement surface of said bracing element.
 34. A wheel according to claim 1, wherein said connecting element includes an extension portion to surround said opening about said opening axis and wherein said extension is located longitudinally outward of said hole.
 35. A wheel according to claim 1, wherein said connecting element is of a polymeric material. 